Supporting pillars for encapsulating a flexible pcb within a soft hydrogel contact lens

ABSTRACT

A contact lens may include a body of contact lens material extending between a first surface and a second surface. An electromechanical component may be supported in the contact lens material between the first surface and the second surface. A support comprising a plurality of pillars may be formed of the contact lens material and may extend from at least one of the first surface and the second surface to the electromechanical component.

RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.17/452,549, filed Oct. 27, 2021, which is a continuation of U.S. patentapplication Ser. No. 17/301,537, filed Apr. 6, 2021, now U.S. Pat. No.11,209,672, issued Dec. 28, 2021, the disclosures of which areincorporated, in their entirety, by this reference.

BACKGROUND

Electronic contact lenses, sometimes referred to as eCLs, are contactlenses that include electrical, mechanical, or other components. Priorelectronic contact lenses are less than ideal for a number of reasons.The electronic contact lenses can be difficult to manufacture in a waythat results in a contact lens that is safe and comfortable for thepatient to wear and the resulting lenses have low durability. Apotential problem that can arise is that the soft contact lens materialcan separate from the electronics.

SUMMARY

The electronic contact lenses disclosed herein, and the disclosedfabrication processes used to manufacture contact lenses, provide for anelectronic contact lens comprising components that are encapsulatedwithin contact lens material and supported by one or more supports. Thecomponents can be configured in many ways and may comprise one or moreof display components, or active components to provide therapy such aslight therapy. In some embodiments, the supports used in themanufacturing process aid in aligning the components between thesurfaces of the contact lens and in encapsulating the electroniccomponents within the body of the contact lens. The supports can besized and shaped in many ways and may comprise pillars to support theelectronical components during fabrication. Encapsulating the componentswithin the body of the contact lens allows for a safer and morecomfortable experience for the patient, and also improves durability ofthe contact lenses.

The fabrication of the contact lens is also improved. Supports formedfrom contact lens material are formed on a mold prior to placing thecomponents in the mold and forming the rest of the contact lens body.The supports aid in accurately positioning the contact lens componentsin the contact lens mold and with respect to the final shape of thecontact lens. The supports also hold the contact lens components in asuspended location within the uncured contact lens material duringfabrication. This allows for better encapsulation of the componentswithin the final contact lens body.

A contact lens may include a body of contact lens material extendingbetween a first surface and a second surface. An electromechanicalcomponent may be suspended in the contact lens material between thefirst surface and the second surface. A support may be formed of thecontact lens material and may extend from at least one of the firstsurface and the second surface to the electromechanical component.

A method of fabricating a contact lens may include forming a support ofcontact lens material on a first contact lens mold. The support ofcontact lens material may be partially cured. Electromechanicalcomponents may be placed on the support. The mold may be filled withcontact lens material. The contact lens material may be cured.

BRIEF DESCRIPTION OF THE DRAWINGS

A better understanding of the features, advantages and principles of thepresent disclosure will be obtained by reference to the followingdetailed description that sets forth illustrative embodiments, and theaccompanying drawings of which:

FIG. 1 shows a contact lens, in accordance with some embodiments;

FIG. 2 shows a contact lens, in accordance with some embodiments;

FIG. 3 shows a system diagram for the electrical and mechanicalcomponents of the contact lens of FIG. 2, in accordance with someembodiments;

FIG. 4A shows a contact lens with supports for supporting the electricaland mechanical components in the contact lens, in accordance with someembodiments;

FIG. 4B shows a cross section of the contact lens with supports of FIG.4A, in accordance with some embodiments;

FIGS. 5A, 5B, 5C, 5D, and 5E show supports formed on contact lens molds,in accordance with some embodiments;

FIGS. 6A and 6B show a support mask, in accordance with someembodiments;

FIGS. 7A and 7B show a support mask, in accordance with someembodiments;

FIG. 8 shows a method of fabricating a contact lens, in accordance withsome embodiments;

FIGS. 9A and 9B depict an apparatus for depositing pillars on a mold, inaccordance with some embodiments;

FIG. 10 shows a support formed on a mold, in accordance with someembodiments;

FIG. 11 shows a fabricated contact lens with a support, in accordancewith some embodiments; and

FIGS. 12 and 13 show a fabricated contact lens with supports andmechanical and electrical components therein, in accordance with someembodiments.

DETAILED DESCRIPTION

The following detailed description and provides a better understandingof the features and advantages of the inventions described in thepresent disclosure in accordance with the embodiments disclosed herein.Although the detailed description includes many specific embodiments,these are provided by way of example only and should not be construed aslimiting the scope of the inventions disclosed herein.

The presently disclosed methods and apparatus can be configured in manyways to provide contact lenses for retinal stimulation, as describedherein.

The presently disclosed methods and apparatus are well suited forcombination with many prior devices such as, one or more of anophthalmic device, a contact lens, an implantable device, a cornealonlay, a corneal inlay, a corneal prosthesis, an intraocular lens, aspectacle lens, a virtual reality (VR) display or an augmented reality(AR) display. Although specific reference is made to contact lenses, thepresently disclosed methods and apparatus are well suited for use withany of the aforementioned devices, and a person of ordinary skill in theart will readily appreciate how one or more of the presently disclosedcomponents can be interchanged among devices, based on the teachingsprovided herein.

The presently disclosed methods and apparatus are well suited for usewith lenses for light therapy to treat refractive error of the eye totreat myopia. Work in relation to the present disclosure suggests thatchanges to choroidal thickness in response to stimulation on regions ofthe eye can be localized to regions near the stimulated regions, whichcan provide a somewhat localized response in accordance with someembodiments. In some embodiments, the changes to one or more of thechoroid or sclera comprise a differential change, in which the changesto the one or more of the choroid or sclera are greater near the regionsof stimulation than at corresponding regions remote from the stimulation(e.g. corresponding locations at an axis 90 degrees from the region ofstimulation).

Work in relation to the present disclosure suggests systems and methodsfor fabricating such lenses may include fabricating supporting pillarsfor supporting electrical and mechanical systems, such as embeddedelectronics and optics, during and after fabrication.

FIGS. 1 and 2 depict a lens such as a contact lens 10 configured toproject a defocused image on the retina away from the central field thatincludes the macula in order to stimulate a change in choroidalthickness. Although reference is made to a contact lens, the lens 10 maycomprise a lens of one or more of a contact lens, a corneal onlay, acorneal inlay, a corneal prosthesis, or an intraocular lens.

In some embodiments, for the treatment of astigmatism, the contact lens10 comprises a first astigmatic axis 80 and a second astigmatic axis 81.The plurality of light sources, such as projection units 12, is arrangedwith respect to the astigmatic axes to provide different amounts ofstimulation to different regions of the peripheral retina. In someembodiments, the light sources such as projection units 12 are locatedalong the astigmatic axis, although the light sources may be located atother locations. The light sources can be configured to providedifferent amounts of stimulation to the peripheral retina in accordancewith the refractive error of the eye. In some embodiments, the lightsources are configured to provide different amounts of illuminationalong different axes in order to promote different changes in choroidaland scleral tissue corresponding to different changes in axial length asdescribed herein. The contact lens may comprise a rotationallystabilized contact lens, and the light sources can be located on thecontact lens so as to correspond to the astigmatic axes of the eye whenthe lens is stabilized on the eye, for example. The contact lens maycomprise an optical zone configured to correct astigmatic refractiveerrors in accordance with the first axis 80 and the second axis 81.

In some embodiments, for the treatment of spherical refractive errors ofthe eye, the plurality of light sources, such as projection units 12,are arranged with symmetrically with respect to central axis of thecontact lens, the center of the contact lens, or another location of thecontact lens. The symmetry may be rotational symmetry, such that thelight sources are arranged on a circumference centered on the locationof the contact lens.

This contact lens 10 comprises a base or carrier contact lens comprisingembedded electronics and optics. The base soft contact lens 10 is madeof a biocompatible material such as a hydrogel or a silicone hydrogelpolymer designed to be comfortable for sustained wear. The contact lenscomprises a maximum overall distance across, e.g. a diameter 13. Thebiocompatible material can encapsulate the components of the softcontact lens 10. For example, the components may be embedded within thebiocompatible material. In some embodiments, the contact lens 10 has acentral optical zone 14 designed to cover the pupil of a wearer undermany illumination conditions. In some embodiments, the optical zonecomprises a circular zone defined with a radius 15. In some embodiments,a plurality of projection units 12 are located a distance 17 from acenter of the optical zone. Each of the plurality of projection units 12comprises a distance across 19. In some embodiments, the distancesbetween the projection units are sized to place the projection unitsoutside the optical zone to stimulate a peripheral region of the retina,although the projection units can also be placed inside the optical zoneto stimulate the peripheral retina as described herein.

The optical zone 14 can be appropriately sized for the pupil of the eyeand the illumination conditions during treatment. In some embodiments,the optical zone comprises a diameter of 6 mm, for example when thecontact lens is configured for use during the day. The optical zone 14may have a of diameter within a range from 6 mm to 9 mm, for examplewithin a range from 7.0 mm to 8.0 mm. The central optical zone 14 isdesigned to provide emmetropic correction or other suitable correctionto the wearer and may be provided with both spherical and astigmaticcorrection. The central optical zone 14 is circumscribed by an outerannular zone, such as a peripheral zone 16 of width in a range 2.5 mm to3.0 mm. The peripheral zone 16, sometimes referred to as the blend zoneis primarily designed to provide a good fit to the cornea, includinggood centration and minimum decentration. The outer annular zone issurrounded by an outermost edge zone 18 of width in the range from 0.5mm to 1.0 mm. The optical zone 14 is configured to provide refractivecorrection and can be spherical, toric or multifocal in design, forexample with a visual acuity of 20/20 or better. The outer annular zoneperipheral to the optical zone 14 is configured to fit the cornealcurvature and may comprise rotational stabilization zones fortranslational and rotational stability, while allowing movement of thecontact lens 10 on the eye following blinks. The edge zone 18 maycomprise a thickness within a range from 0.05 mm to 0.15 mm and may endin a wedge shape. The overall diameter 13 of the soft contact lens 10can be within a range from 12.5 mm to 15.0 mm, for example within arange from 13.5 mm to 14.8 mm.

The contact lens 10 includes a plurality of embedded projection units12. Each of the plurality of projection units 12 comprises a lightsource and one or more optics to focus light in front of the retina asdescribed herein. Each of the optics may comprise one or more of amirror, a plurality of mirrors, a lens, a plurality of lenses, adiffractive optic, a Fresnel lens, a light pipe or a wave guide. Thecontact lens 10 may comprise a battery 20 and a sensor 22. The contactlens 10 may comprise a flex printed circuit board (PCB) 24, and aprocessor can be mounted on the flex PCB 24. The processor can bemounted on the PCB 24 and coupled to the sensor 22 and the plurality oflight sources 30. The soft contact lens 10 may also comprise wirelesscommunication circuitry and one or more antennae 41 for electroniccommunication and for inductively charging the battery 20 of the contactlens 10. Although reference is made to a battery 20, the contact lens 10may comprise any suitable energy storage device.

The projection units 12 can be configured to provide defocused images tothe peripheral portion of the retina as described herein and may includelight sources and projection optics. In some embodiments, one or moreprojection optics are configured with the light sources to project adefocused image from the light sources onto the peripheral retina awayfrom the central visual field that includes the macula in order tostimulate a change in choroidal thickness, such as an increase ordecrease in cordial thickness. The one or more projection units 12 canbe configured to stimulate the retina without degrading central visionand corresponding images formed on one or more of the foveal or macularregions of the retina. In some embodiments, the one or more projectionoptics do not decrease the image forming characteristics of the visioncorrection optics prescribed to correct refractive errors of thewearers. This configuration can allow the wearer to have good visualacuity while receiving therapy from the defocused images as describedherein.

In some embodiments, the light from light sources of the projectionunits 12 are calumniated and focused by one or more projection optics,as described herein. The function of the light sources and theprojection optics is to substantially collimate the light emitted by thelight sources and focus it at a focus that is designed to be in thefront of or behind the retina to provide appropriate defocus tostimulate a change in choroidal thickness. For myopic defocus, thefocused images may appear approximately 1.5 mm to 2.5 mm in front of theperipheral retina and myopic by about 2.0 D to 5.0 D, for example 2.0 Dto 4.0 D, or preferably 2.5 D to 3.5 D, for example. For hyperopicdefocus, he focused images may appear approximately 1.5 mm to 2.5 mmbehind of the peripheral retina, in order to be hyperopic by about −2.0D to 5.0 D, for example −2.0 D to −4.0 D, or preferably −2.5 D to −3.5D, for example.

In accordance with some embodiments, a soft contact lens 10 comprisesprojection units which include projection optics and micro-displays asthe light source. The micro-displays may comprise an OLED (organic lightemitting diode) or an array of micro-LEDs. Light emitted by thesedisplays may be Lambertian. In some embodiments, the micro-display isoptically coupled to a micro-optical array that substantially collimatesand focuses the light emanating from the micro-display. Themicro-display may comprise one or more miniaturized pixels. In someembodiments, the micro-display forms an extended array of pixels,characterized by a pixel size and a pixel pitch, in which the pixel sizeand the pixel pitch together correspond to a fill factor of themicro-display. As described herein, each of the pixels may have a sizewithin a range from about 2 microns to about 100 microns, and the pixelpitch may range from 10 microns to 1.0 mm, for example. Thecorresponding fill factor can range from 0.1% to 10%. In someembodiments, the pixel array is optically coupled with a micro-opticarray in order to substantially collimate and focus light from thepixels.

The images created by these displays is defocused and may be placedsymmetrically in four quadrants of the field of view or of the eye (e.g.nasal-inferior, nasal-superior, temporal-inferior andtemporal-superior). The micro displays can be located away from theoptical center of the lens by a distance within a range from 1.5 mm to4.0 mm, preferably 2.5 mm to 3.5 mm. The central optic of the contactlens can be selected to bring the wearer to emmetropia, and may have adiameter within a range 3.0 to 5.0 mm. Each micro-display may becircular, rectangular or arcuate in shape and have an area within arange from 0.01 mm2 to 8.0 mm2, for example within a range from 0.04 mm2to 8.0 mm2, for example within a range from 1 mm2 to 8 mm2, orpreferably within a range from 1.0 mm2 to 4.0 mm2, in some embodiments.

The micro-display can be coupled to and supported with the body of thecorrection optic such as a contact lens, for example. In someembodiments, the micro-displays are coupled to and supported with one ormore of an intraocular lens, a corneal prosthesis, a corneal onlay, or acorneal inlay. The optical configurations described herein withreference to a contact lens can be similarly used with one or more of anintraocular lens, a corneal prosthesis, a corneal onlay, or a cornealinlay, for example.

In some embodiments, the micro-displays and the micro-optic arrays aremounted immediately adjacent to each other on the same correction optic,separated by a fixed distance in order to project a bundle of rays tothe pupil of the eye, at an orientation that it forms a defocused imageat a desired location on the retina as described herein. In someembodiments, the one or more projection optics are mounted on or in theone or more correction optics, such that rays from the projection opticsare refracted through the correction optics. The correction opticsrefract the rays from the projection optics to be convergent ordivergent as helpful for clear vision, so that the micro-optical arraycan provide the desired magnitude of additional power that may be plusor minus, depending on the magnitude and sign of the defocus desired.The micro-display may be monochromatic or polychromatic, for example.

In some embodiments, the projected defocused image can be provided by amicro-display comprising a screen comprising one or more of an LCDscreen, a screen driven by OLEDS (organic light emitting diodes),TOLEDS, AMOLEDS, PMOLEDS, or QLEDS. The screen may appear to the subjectat a far distance of east least 6 meters or more, for example.

FIG. 3 shows mechanical integration of the function of the components ofa retinal stimulation device, such as a contact lens 10 as in FIG. 2.Although reference is made to mechanical integration with a contactlens, similar integration can be performed with any vision device asdescribed herein. These components can be supported with the PCB 24. Forexample, the power source such as a battery 20 can be mounted on the PCB24 and coupled to other components to provide a power source function21. The sensor 22 can be configured to provide an activation function23. The sensor 22 can be coupled to a processor mounted on the PCB 24 toprovide a control function 25 of the contact lens 10. The controlfunction 25 may comprise a light intensity setting 27 and a light switch29. The processor can be configured to detect signal from the sensor 22corresponding to an increase in intensity, a decrease in intensity, oran on/off signal from the sensor 22, for example with a coded sequenceof signals from the sensor 22. The processor is coupled to the lightprojection units 18 which can comprise a light source 30 and optics 32to provide the projection function 31. For example, the processor can becoupled to the plurality of light sources 30 to control each of thelight sources 30 in response to user input to the sensor 22.

The retinal stimulation device may comprise global positioning system(GPS) circuitry for determining the location of the wearer, and anaccelerometer to measure body movement such as head movement. Theretinal stimulation device may comprise a processor coupled to one ormore of the GPS or the accelerometer to receive and store measured data.The retinal stimulation device may comprise communication circuitry suchas wireless communication circuitry, e.g. Bluetooth or WiFi, or wiredcommunication circuitry, e.g. a USB, in order to transmit data from thedevice to a remote server, such as a cloud-based data storage system.This transmission of data to the remote server can allow the treatmentand compliance of the wearer to be monitored remotely. In someembodiments, the processor comprises a graphics processing unit (GPU).The GPU can be used to efficiently and rapidly process content from theweb in order to utilize this content in forming the stimulus asdescribed herein.

The methods and apparatus for retinal stimulation as described hereincan be configured in many ways and may comprise one or more attributesto encourage a user to receive therapy. For example, the retinalstimulation as described herein can be combined with a display of a gameto encourage a user to wear the treatment device. In some embodiments,the retinal stimulation can be combined with another stimulus, such asan emoji, e.g. a smiley face, to encourage a user to wear the device fortreatment. The components of the system may communicate with or receiveinformation from a game or other stimulus to facilitate the retinalstimulation with the game or stimulus.

FIGS. 4A and 4B show a contact lens 10 with supports such as pillars forsupporting the electrical and mechanical components in the contact lens.The contact lens 10 is configured to project a defocused image on theretina away from the central field that includes the macula in order tostimulate a change in choroidal thickness as described herein. Thecontact lens 10 may include a plurality of components, such asprojection units 12. Each of the plurality of projection units 12comprises a light source and one or more optics to focus light in frontof the retina as described herein. Each of the optics may comprise oneor more of a mirror, a plurality of mirrors, a lens, a plurality oflenses, a diffractive optic, a Fresnel lens, a light pipe or a waveguide. The contact lens 10 may comprise other components, such as abattery and processor system 20 and a sensor 22. The contact lens 10 maycomprise a flex printed circuit board (PCB) 24, and a processor can bemounted on the flex PCB 24. The processor can be mounted on the PCB 24and coupled to the sensor 22 and the plurality of light sources 12. Thesoft contact lens 10 may also comprise wireless communication circuitryand one or more antennae 41 for electronic communication and forinductively charging the battery 20 of the contact lens 10.

The contact lens my include a body of contact lens material that is abiocompatible material that can encapsulate the components of the softcontact lens 10. The contact lens may also include one or more supports40 for supporting the components within the contact lens body. Forexample, the supports may be formed during the fabrication process tohold or suspend the components away from molds used to form the lensbody. In this way, uncured lens material is able to flow around thesupported components during fabrication. Then, the lens material iscured with the suspended and encapsulated components therein. Theprocesses and structures described herein allow the formation of acontact lens with electromechanical components fully encapsulated withinthe lens material and may avoid electromechanical components fromprotruding the lens body. In some embodiments, the material may be a lowswell material, such as that described in U.S. Pat. App. Pub.2008/0291391, titled “Hybrid Contact Lenses Prepared with ExpansionControlled Polymeric Material,” filed May 25, 2007. In some embodiments,the contact lens material may be a zero-swell material. The soft contactlens material may comprise any suitable material, such as a hydrogel, asilicone, or other suitable material such as a polymeric material thatcomprises recurring units selected from the group consisting of(meth)acrylic monomers including linear (siloxanyl)alkyl(meth)acrylates, branched (siloxanyl)alkyl (meth)acrylates, and cyclic(siloxanyl)alkyl (meth)acrylates, silicone-containing (meth)acrylates,fluorine-containing (meth)acrylates, hydroxyl group containing(meth)acrylates, (meth)acrylic acid, N-(meth)acryloylpyrrolidone,(meth)acrylamides, aminoalkyl (meth)acrylates, alkoxy group-containing(meth)acrylates, aromatic group containing (meth)acrylates, glycidyl(meth)acrylate, tetrahydrofurfuryl (meth)acrylate, silicone-containingstyrene derivatives, fluorine-containing styrene derivatives, styrenederivatives, and vinyl monomers.

The location of the supports 40 may be configured in many ways. Thelocation of the supports 40 may be determined based on the location ofthe components within the contact lens 10. For example, the PCB 24 thatelectrically couples the light sources 12 to the other components mayform a concentric ring or a partial concentric ring about the clearcentral zone 14 of the contact lens. The PCB supports 40 a may also bearranged in a concentric ring located about the clear central zone 14 ofthe contact lens at locations corresponding to the location of the PCB24. In some embodiments, the supports 40 a may be arranged in a circulararray with supports at regular angular intervals or with regular spacingbetween adjacent supports 40 a.

In some embodiments, the contact lens 10 may include an antenna 41. Theantenna 41 may be located near the outer perimeter of the contact lens10. In some embodiments, the antenna may form a ring or partial ringproximate the outer perimeter of the contact lens 10. In someembodiments, antenna supports 40 b may also be arranged in a concentricring located proximate the outer perimeter of the contact lens 10 atlocations corresponding to the location of the antenna 41. In someembodiments, the supports 40 b may be arranged in a circular array withsupports at regular angular intervals or with regular spacing betweenadjacent supports 40 b. In some embodiments, the supports are arrangedin two concentric rings about the center of the contact lens. A first ofthe concentric rings supporting the PCB and a second of the concentricrings supporting the antenna.

In some embodiments, the supports 40 may be arranged in pairs, forexample supports 40 c are arranged in pairs. A pair of supports 40 c maybe located immediately adjacent to each other. In some embodiments, afirst of a pair of supports 40 c may be located at a location on a firstside of a component and a second of the pair of supports 40 c may belocated on a second side of a component. For example, in someembodiments, the supports may form hemispherical shapes. A valley orchannel may be formed between a pair of adjacent hemispherical supports.The valley or channel may be at a location that corresponds to thelocation of the component that is to be supported by the support, suchas antenna 41.

Although only a single pair of supports 40 c are depicted in FIG. 4A, apair supports may be located at any location that an individual support40 may be located. For example, the pairs of supports 40 c may bearranged in a circular array at regular intervals or at regular spacingbetween the adjacent pairs of supports 40 c in order to support anantenna 41 or PCB 24. In some embodiments, the pairs of supports may belocated about any location where a narrow component may be supported.

In some embodiments, supports 40 may be arranged in a two-dimensionalarray. For example, supports 40 d are arranged in a 2×3 two-dimensionalarray beneath the sensor component 22. A two-dimensional array ofsupports may be useful in supporting larger components, such as asensor, a battery, a processor, and other larger components. Thesupports 40 d may be arranged at regular intervals between each other.In some embodiments, the intervals between supports may differ. Forexample, the two-dimensional array may have columns and rows ofsupports. The intervals or distance between adjacent columns of supportsmay vary and may be different than the intervals or distance betweenadjacent rows of supports. In some embodiments, the interval or distancebetween adjacent rows of supports may vary and may be different than theintervals or distance between adjacent columns of supports.

In some embodiments, supports 40 may have different sizes and shapes.For example, support 40 e has a larger dimension, such as a diameter,than the other supports depicted in FIG. 4A.

In some embodiments, adjacent supports may be separated from each otherby a distance. The distance between supports may be between 0.1 mm and 3mm. In some embodiments, the distance between supports may be less than2 mm. In some embodiments, the distance between supports may be lessthan 1 mm. In some embodiments, the distance between supports may beabout 0.1 mm, 0.25 mm, 0.5 mm, 0.75 mm, 1.0 mm, 1.25 mm, 1.5 mm, 1.75mm, or 2 mm.

In some embodiments, the distance between supports may be a relativedistance. For example, in some embodiments, the distance betweensupports may be based on the diameter, height, width, or other dimensionof the support. In some embodiments, the supports may be about one halfthe dimension from each other. In some embodiments, the supports may bebetween 0.1 and 6.0 dimensions of each other.

In some embodiments, the distance between supports may be measured fromthe outer perimeter of the adjacent supports. In some embodiments, thedistance between supports may be measured from a center of the support.

In some embodiments, the supports may be arranged in differingdensities. The density of the supports may be defined by the surfacearea of the supports as compared to the surface area of the componentthat the supports support. For example, the supports 40 d may bearranged at a first density of less than 10% while the supports may bearranged at a second density of greater than 30%. In some embodiments,the support density may be 100%. In some embodiments, the supportdensity may be between about 10% and less than 100%. In someembodiments, the support density may be between about 30% and about 60%.

In some embodiments, some of the supports may be located in positionswithin the contact lens that do not correspond to the location ofelectromechanical components. In some embodiments the ratio supports inlocations that correspond to a location of electromechanical componentsto supports in locations that do not correspond to a location ofelectromechanical components is greater than 3 to 1. In some embodimentsthe ratio is preferably greater than 5 to 1 in more preferably greaterthan 10 to 1 in order to decrease the number of pillars that do notsupport electromechanical components.

In some embodiments, one or more supports is dimensioned to position aflexible printed circuit board (PCB) with a gap between the flex PCB anda contact lens mold from which the one or more supports extends. The oneor more supports may comprise a plurality of supports, in which the gapbetween the flex PCB and the contact lens mold extends around each ofthe plurality of supports. In some embodiments, the gap is dimensionedto receive flowable material for curing to form the contact lens body.While the gap can be dimensioned in many ways to receive the flowablematerial, in some embodiments the gap comprises distance extending fromflex PCB toward the contact lens mold and is within a range from 0.010mm to 0.3 mm, and optionally within a range from 0.040 mm to 0.2 mm. Insome embodiments, the gap extends from a surface of the flex PCB to asurface of the contact lens mold from which the support extends.Alternatively or in combination, the gap may extend from the flex PCB toa thin layer of polymer material on the contact lens mold from which theone or more supports extends as described herein.

FIG. 4B shows a cross section of the contact lens with supports of FIG.4A. As depicted in FIG. 4B, supports 40 may extend from one or bothsides of the contact lens 10. In some embodiments, supports may extendfrom only a side of the contact lens that faces the eye, while in someembodiments, supports may extend from only the side of the contact lensthat faces away from the eye. As shown in FIG. 4B, the supports 40extend from a surface of the contact lens in order to hold or suspendthe components of the contact lens, such as the PCB 24, within thecontact lens material. In this way, the components are suspended orencapsulated within the contact lens material.

The supports 40 may have a width or diameter 44. The width or diameter44 may be between about 0.05 mm and about 2.0 millimeters, preferablybetween about 0.3 mm and about 1 mm. In some embodiments, the diameteror width 44 of the supports 40 may be sized relative to the componentthat the support supports. For example, in some embodiments, the widthor diameter 44 may be equal to or less than the width or diameter of thecomponent. In some embodiments, the width or diameter 44 of the supportmay be between 20% and 120% of the width of or diameter of the componentit is supporting. In some embodiments, the width or diameter 44 of thesupport may be between 20% and 80% of the width or diameter of thecomponent it is supporting. In some embodiments, the width or diameterof the support may be less than about 100%, 90%, 80%, 70%, 60%, 50%,40%, 30%, or 20% of the width of the component it is supporting.

The supports 40 may extend from a surface of the contact lens with aheight 42. The height of the support may be between 0.010 mm and 0.3 mm.In some embodiments, the height of the support may be between 0.040 mmand 0.2 mm. In some embodiments, the height of the support may be basedon the thickness 46 of the contact lens 10. In some embodiments, theheight of the support is less than 50% of the thickness of the contactlens 10. In some embodiments, the height of the support is between 20%and 80% of the thickness of the contact lens 10. In some embodiments,the height of the support is between 30% and 70% of the thickness of thecontact lens 10. In some embodiments, the height of the support isbetween 40% and 60% of the thickness of the contact lens 10. In someembodiments, the support extends from at least one of the surfaces ofthe contact lens with a height of at least 0.02 mm.

In some embodiments, the supports 40 may have a defined volume. Thevolume of the support may be between about 0.005 uL and 0.5 uL. In someembodiments, the volume of the supports may be between 0.01 uL and 0.1uL.

In some embodiments, for example for supports arranged in a circulararray, the supports may be located an angular distance from each other.For example, in some embodiments, the supports may be located between10° and 30° from each other. In some embodiments, the supports arelocated about 10°, about 15°, about 20°, about 25°, about 30°, about35°, about 40°, or about 45° from each other.

FIGS. 5A, 5B, 5C, 5D, and 5E show supports formed on contact lens molds.FIG. 5A shows a plurality of supports 40 formed on a concave mold 400 a.The supports 40 are deposited on the surface of the mold 400 a whileleaving the central optical zone 14 clear of supports. The supports 40may be deposited on the mold by any means. For example, in someembodiments, the supports are individually deposited, one at a time, inan automated process. In some embodiments, a computer numerical controlmachine (CNC) may be programmed to move to the desired locations anddispense a volume of contact lens material onto the mold in order toform the support. In some embodiments, the contact lens material may bedeposited via a pipette for other volumetric metering device. In someembodiments, an array of dispensers arranged according to the desiredlocations of the supports may simultaneously dispense a plurality ofsupports on the concave mold 400 a. In some embodiments, a directfabrication machine, such as a 3D printer, may deposit the contact lensmaterial at the desired locations of the concave mold.

FIG. 5B shows a plurality of supports 40 formed on a convex mold 400 b.The supports 40 are deposited on the surface of the mold 400 b whileleaving the central optical zone 14 clear of supports. The supports 40may be deposited on the mold by any means. For example, in someembodiments, the supports are individually deposited, one at a time, inan automated process. In some embodiments, a computer numerical controlmachine (CNC) may be programmed to move to the desired locations anddispense a volume of contact lens material onto the mold in order toform the support. In some embodiments, the contact lens material may bedeposited via a pipette for other volumetric metering device. In someembodiments, an array of dispensers arranged according to the desiredlocations of the supports may simultaneously dispense a plurality ofsupports on the convex mold 400 b.

In some embodiments, a direct fabrication machine, such as a 3D printer,may deposit the contact lens material at the desired locations of theconvex mold. In some embodiments, the contact lens material may be anuncured monomer. In some embodiments, in order to facilitate depositionof the contact lens material in the desired locations, the contact lensmaterial may be partially cured.

In some embodiments, the surface tension of the drops and/or the degreeof wetting between the contact lens material and the mold may becontrolled in order to aid in preventing undesired movement of thedeposited contact lens material and an order for the contact lensmaterial to form a meniscus on the mold. In some embodiments, thewetting angle between the contact lens material of the support and themold is between 10° and 150°. In some embodiments, the wetting angle isbetween 10° and 90°. In some embodiments, the wetting angle it is lessthan 90°. In some embodiments, the wetting angle is greater than 10°.

In some embodiments, after the uncured or partially cured contact lensmaterial is deposited onto the mold, the uncured or partially curedcontact lens material is put through curing process. In someembodiments, the contact lens material of the supports is fully curedduring the curing process. In some embodiments, the contact lensmaterial is partially cured during the curing process. In someembodiments, after curing the supports, the contact lens components areplaced on the supports. Partially cured supports may provide greateradhesion between the contact lens components and the supports ascompared to fully cured supports thereby aiding in the contact lensfabrication process.

In some embodiments, after curing, a region of slightly decreasedstrength in the contact lens may be formed at the interface between thepillar and the contact lens body, such that the pillar can be detected.In some embodiments, the pillar can be detected by sectioning thecontact lens. Alternatively or in combination, the interface may allowfor separation of the pillar from the contact lens body withexperimental testing, e.g. with tweezers, although such separationtypically will not occur during normal wear and usage of the contactlens. In some embodiments, the region of decreased strength may beformed based on different times of curing of the polymer at theinterface, different amounts of cross-linking at the interface betweenthe pillar and the contact lens body, and differing amounts or degreesof curing. For example, the pillars may have been subjected to twocuring phases while the rest of the contact lens body may have beensubjected to a single curing phase. Alternatively or in combination, thecuring of the support prior to the rest of the material, can result infewer covalent bonds extending across the interface as compared to thebulk polymer material in either the supporting pillars or the contactlens body surrounding the supporting pillars.

FIGS. 5C and 5D depict a variation of the support fabrication process.In some embodiments, a thin film 420 of contact lens material may beformed on the surface of the mold prior to the formation of the supports40 on the thin film 420. In some embodiments, the thin film 420 isformed by depositing the contact lens material to the mold and thenspinning the mold in order to spread out and thin the contact lensmaterial on the mold 400. The thin layer may be between 0.001 mm and0.05 mm thick. In some embodiments, the thin layer may be between 0.005mm and 0.02 mm thick.

After the thin layer contact lens materials formed on the mold, the thinlayer may be cured. In some embodiments, the thin layer 420 may be fullycured. In some embodiments, the thin layer 420 may be partially cured.

After curing the thin layer 420, supports 40 may be deposited onto thethin layer 420 contact lens material. The supports 40 may be depositedon the thin layer 420 by any means. For example, in some embodiments,the supports are individually deposited, one at a time, in an automatedprocess. In some embodiments, a computer numerical control machine (CNC)may be programmed to move to the desired locations and dispense a volumeof contact lens material onto the thin layer 420 in order to form thesupport. In some embodiments, the contact lens material may be depositedvia a pipette or other volumetric metering device. In some embodiments,an array of dispensers arranged according to the desired locations ofthe supports may simultaneously dispense a plurality of supports on thethin layer 420.

In some embodiments, a direct fabrication machine, such as a 3D printer,may deposit the contact lens material at the desired locations of thethin layer 420. In some embodiments, the contact lens material may be anuncured monomer. In some embodiments, in order to facilitate depositionof the contact lens material in the desired locations, the contact lensmaterial may be partially cured.

In some embodiments, the surface tension of the drops and/or the degreeof wetting between the contact lens material and the thin layer 420 maybe controlled in order to aid in decreasing undesired movement of thedeposited contact lens material and an order for the contact lensmaterial to form a meniscus on the thin layer 420. In some embodiments,the wetting angle is between 10° and 150°. In some embodiments, thewetting angle is between 10° and 90°. In some embodiments, the wettingangle it is less than 90°. In some embodiments, the wetting angle isgreater than 10°.

In some embodiments, after the uncured or partially cured contact lensmaterial is deposited onto the thin layer 420 the uncured or partiallycured contact lens material is put through curing process. In someembodiments, the contact lens material of the supports is fully curedduring the curing process. In some embodiments, the contact lensmaterial is partially cured during the curing process.

FIG. 5E shows a variation of the support fabrication process. In someembodiments, a layer 430 of contact lens material may be formed on thesurface of the mold prior to the formation of the supports 40. In someembodiments, the layer 430 is formed by depositing the contact lensmaterial to the mold and then spinning the mold in order to spread outand thin the contact lens material on the mold 400 to a desiredthickness. The thickness of the layer 430 may be the same as the desiredheight of the supports 40.

After the layer of contact lens material is formed on the mold, thelayer may be selectively cured. In some embodiments, the layer 430 maybe selectively fully cured. In some embodiments, the layer 430 may beselectively partially cured. The selectively cured portions of the layer430 may form the supports of the contact lens. The selected curingprocess may be carried out using a mask, for example, as shown anddescribed with respect to FIGS. 7A and 7B. In some embodiments, theuncured contact lens material may be washed off the mold 400. In someembodiments, the uncured contact lens material may remain on the mold400.

FIGS. 6A and 6B show a mask 600 that may be used in forming supports 40.The mask 600 may include a mask body 608 with a plurality of wells 606formed through the mask body 608. A well 606 may be an apertureextending through the body 608 of the mask 600. For example, in someembodiments, a well 606 may extend from a first surface of the mask to asecond surface of the mask to form an aperture through the body 608 ofthe mask 600. In some embodiments, the wells 606 are arranged accordingto the position of the components of the contact lens 10. For example,in some embodiments, wells 606 may form a plurality of arcuate aperturesthrough the mask to form supports to support an antenna. In someembodiments, the wells may be shaped according to the shape of a PCB orlight sources in order to support the PCB and light sources. In someembodiments, the wells may have a shape that corresponds to the shape ofother components such as sensors, processors, batteries, and othercomponents. In some embodiments, the dimensions of the wells correspondto a projection of the contact lens components on the contact lens. Insome embodiments, the dimensions of the wells are smaller than aprojection of the contact lens components on the contact lens.

While the mask 600 depicted in FIG. 6A has wells that correspond to theshape of the components of the contact lens. In some embodiments, thewells may have other shapes and locations. For example, the wells mayhave shapes and locations that correspond to the desired shape andlocation of supports 40 as shown and described herein, for example withrespect to FIG. 4A.

In some embodiments, the wells 606 may be arranged in a circular arrayat regular angular intervals or with regular spacing between adjacentwells 606. In some embodiments, the wells 606 are arranged in twoconcentric rings about the center of the mask 600. A first of theconcentric rings for forming supports for supporting the PCB and asecond of the concentric rings for forming supports for supporting theantenna.

In some embodiments, the wells 606 may be arranged in pairs. A pair ofwells 606 may be located immediately adjacent to each other. In someembodiments, wells 606 are arranged in a 2×3 two-dimensional array forsupporting a sensor component 22. The wells 606 may be arranged atregular intervals between each other. In some embodiments, the intervalsbetween wells 606 may differ. For example, the two-dimensional array mayhave columns and rows of wells 606. The intervals or distance betweenadjacent columns of wells 606 may vary and may be different than theintervals or distance between adjacent rows of wells 606. In someembodiments, the interval or distance between adjacent rows of wells 606may vary and may be different than the intervals or distance betweenadjacent columns of wells 606.

In some embodiments, adjacent wells 606 may be separated from each otherby a distance. The distance between supports may be between 0.1 mm and 3mm. In some embodiments, the distance between wells 606 may be betweenless than less than 2 mm. In some embodiments, the distance betweenwells 606 may be less than 1 mm. In some embodiments, the distancebetween wells 606 may be about 0.1 mm, 0.25 mm, 0.5 mm, 0.75 mm, 1.0 mm,1.25 mm, 1.5 mm, 1.75 mm, or 2 mm.

In some embodiments, the distance between wells 606 may be a relativedistance. For example, in some embodiments, the distance between wells606 may be based on the diameter, height, width, or other dimension ofthe wells 606. In some embodiments, the wells 606 may be a distance ofabout one half the dimension from each other. In some embodiments, thewells 606 may be between 0.1 and 3.0 dimensions of each other.

In some embodiments, the distance between wells 606 may be measured fromthe outer perimeter of the adjacent wells 606. In some embodiments, thedistance between wells 606 may be measured from a center of the wells606.

In some embodiments, the wells 606 may be arranged in differingdensities. For example, the wells 606 may be arranged at a first densityof less than 10% while other wells 606 may be arranged at a seconddensity of greater than 30%. In some embodiments, the wells 606 densitymay be between about 10% and less than 100%. In some embodiments, thewells 606 density may be between about 30% and about 60%.

The wells 606 may have a width or diameter. The width or diameter may bebetween about 0.05 mm and about 2.0 millimeters, preferably betweenabout 0.3 mm and about 1 mm. In some embodiments, the diameter or widthof the wells 606 may be sized relative to the component that a supportformed from the wells will support. For example, in some embodiments,the width or diameter 44 may be equal to or less than the width ordiameter of the component. In some embodiments, the width or diameter ofthe wells 606 may be between 20% and 120% of the width of or diameter ofthe component a support formed from the well will support. In someembodiments, the width or diameter of the wells 606 may be between 20%and 80% of the width or diameter of the component formed in the willsupport. In some embodiments, the width or diameter of the wells 606 maybe less than about 100%, 90%, 80%, 70%, 60%, 50%, 40%, 30%, or 20% ofthe width of the component formed from the well will support.

The wells 606 may have a depth 610. The depth 610 of the well may definethe height a support formed within the well. The depth of the well maybe between 0.010 mm and 0.3 mm. In some embodiments, the depth 610 ofthe well 606 may be between 0.040 mm and 0.2 mm. In some embodiments,the depth 610 of the wells 606 may be based on the thickness of thecontact lens 10. In some embodiments, the depth 610 of the wells 606 isless than 50% of the thickness of the contact lens 10. In someembodiments, the depth 610 of the wells 606 is between 20% and 80% ofthe thickness of the contact lens 10. In some embodiments, the depth 610of the wells 606 is between 30% and 70% of the thickness of the contactlens 10. In some embodiments, the depth 610 of the wells 606 is between40% and 60% of the thickness of the contact lens 10. In someembodiments, the depth 610 of the wells 606 is at least 0.02 mm.

In some embodiments, the wells 606 may have a defined volume. The volumeof the wells 606 may be between about 0.005 uL and 0.5 uL. In someembodiments, the volume of the wells 606 may be between 0.01 uL and 0.1uL.

In some embodiments, fabricating supports using a mask, such as the mask600, may start by placing the mask 600 on a mold, such as any of themolds described herein. Contact lens material may then be depositedwithin the wells 606 of the mask body 608. After the contact lensmaterial is deposited within the well 606 the contact lens material maybe cured. In some embodiments, the contact lens material may be fullycured. In some embodiments, the contact lens material may be partiallycured. In some embodiments, the contact lens material is at leastpartially cured such that it adheres to the mold more strongly than itadheres to the mask body 608. By only curing the contact lens materialsuch that it adheres to the mold more strongly than it adheres to themask body, the mask body may be removed from the mold while the supportsformed within the wells remain on the mold.

In some embodiments, the mask is inserted into a concave mold while insome embodiments, the mask is placed on a convex mold.

FIGS. 7A and 7B show a mask 700 that may be used in forming supports 40.The mask 700 may include a mask body 708 with a plurality of apertures706 formed through the mask body 708. In some embodiments, an aperture706 may extend from a first surface of the mask to a second surface ofthe mask to form the aperture through the body 708 of the mask 700. Insome embodiments, the mask body 708 is configured to prevent curingradiation, such as visible or ultraviolet light, from passing thoughbody 708 while the apertures 706 transmit curing radiation. In someembodiments, the apertures are empty. In some embodiments, the aperturesmay be covered or filed with material that transmits curing radiation,such as ultraviolet light.

In some embodiments, the apertures 706 are arranged according to theposition of the components of the contact lens 10. For example, in someembodiments, apertures 706 may form a plurality of arcuate aperturesthrough the mask body for the formation of supports to support anantenna. In some embodiments, the apertures may be shaped according tothe shape of a PCB and light sources, in order to support the PCB andlight sources. In some embodiments, the apertures may have a shape thatcorresponds to the shape of other components such as sensors,processors, batteries, and other components. In some embodiments, thedimensions of the apertures correspond to a projection of the contactlens components on the contact lens. In some embodiments, the dimensionsof the apertures are smaller than a projection of the contact lenscomponents on the contact lens.

While the mask 700 depicted in FIG. 7A has apertures that correspond tothe shape of the components of the contact lens. In some embodiments,the apertures may have other shapes and locations. For example, theapertures may have shapes and locations that correspond to the desiredshape and location of supports 40 as shown and described herein, forexample with respect to FIG. 4A.

In some embodiments, the apertures 706 may be arranged in a circulararray at regular angular intervals or with regular spacing betweenadjacent apertures 706. In some embodiments, the apertures 706 arearranged in two concentric rings about the center of the mask 700. Afirst of the concentric rings for forming supports for supporting thePCB and a second of the concentric rings for forming supports forsupporting the antenna.

In some embodiments, the apertures 706 may be arranged in pairs. A pairof apertures 706 may be located immediately adjacent to each other. Insome embodiments, apertures 706 are arranged in a 2×3 two-dimensionalarray for supporting a sensor component 22. The apertures 706 may bearranged at regular intervals between each other. In some embodiments,the intervals between apertures 706 may differ. For example, thetwo-dimensional array may have columns and rows of apertures 706. Theintervals or distance between adjacent columns of apertures 706 may varyand may be different than the intervals or distance between adjacentrows of apertures 706. In some embodiments, the interval or distancebetween adjacent rows of apertures 706 may vary and may be differentthan the intervals or distance between adjacent columns of apertures706.

In some embodiments, adjacent apertures 706 may be separated from eachother by a distance. The distance between supports may be between 0.1 mmand 3 mm. In some embodiments, the distance between apertures 706 may bebetween less than less than 2 mm. In some embodiments, the distancebetween apertures 706 may be less than 1 mm. In some embodiments, thedistance between apertures 706 may be about 0.1 mm, 0.25 mm, 0.5 mm,0.75 mm, 1.0 mm, 1.25 mm, 1.5 mm, 1.75 mm, or 2 mm.

In some embodiments, the distance between apertures 706 may be arelative distance. For example, in some embodiments, the distancebetween apertures 706 may be based on the diameter, width, or otherdimension of the apertures 706. In some embodiments, the distance may bebased on a height of a support to be formed with the aperture. In someembodiments, the apertures 706 may be a distance of about one half thedimension from each other. In some embodiments, the apertures 706 may bebetween 0.1 and 3.0 dimensions of each other.

In some embodiments, the distance between apertures 706 may be measuredfrom the outer perimeter of the adjacent apertures 706. In someembodiments, the distance between apertures 706 may be measured from acenter of the apertures 706.

In some embodiments, the apertures 706 may be arranged in differingdensities. For example, the apertures 706 may be arranged at a firstdensity of less than 10% while other apertures 706 may be arranged at asecond density of greater than 30%. In some embodiments, the apertures706 density may be between about 10% and less than 100%. In someembodiments, the apertures 706 density may be between about 30% andabout 60%.

The apertures 706 may have a width or diameter. The width or diametermay be between about 0.05 mm and about 2.0 millimeters, preferablybetween about 0.3 mm and about 1 mm. In some embodiments, the diameteror width of the apertures 706 may be sized relative to the componentthat a support formed from the apertures will support. For example, insome embodiments, the width or diameter may be equal to or less than thewidth or diameter of the component. In some embodiments, the width ordiameter of the apertures 706 may be between 20% and 120% of the widthof or diameter of the component a support formed from the aperture willsupport. In some embodiments, the width or diameter of the apertures 706may be between 20% and 80% of the width or diameter of the componentformed in the will support. In some embodiments, the width or diameterof the apertures 706 may be less than about 100%, 90%, 80%, 70%, 60%,50%, 40%, 30%, or 20% of the width of the component formed from theaperture will support.

In some embodiments, fabricating supports using a mask, such as the mask700, may start by depositing a layer 420 of contact lens material on themold 400. In some embodiments, depositing the layer 420 of contact lensmaterial on the mold 400 includes spin forming the material on the moldin order to spread out and thin the contact lens material to a desiredthickness. Then, the mask 700 is placed between a curing radiationsource, such as a UV light source, and the uncured contact lensmaterial. The curing radiation source is then activated to emit curingradiation, such as UV or visible light 720. The UV light 720 passesthrough the apertures 708 and selectively cures unmasked portions 722 ofthe layer 420 of contact lens material to form supports 40. In someembodiments, the contact lens material may be partially cured atsupports 40. In some embodiments, the contact lens material is fullycured at supports 40. In some embodiments, after at least partiallycuring the contact lens material at the selected location 722, theuncured contact lens material that was not exposed to curing radiationis washed off the mold. In some embodiments, the uncured contact lensmaterial that was not exposed to curing radiation is not washed off themold and the components placed on both the at least partially curedsupports 40 and the uncured material of layer 720.

The light 720 can be configured in many ways, and may comprise anysuitable wavelength such as visible or ultraviolet light, or otherwavelengths of light, and the electromagnetic radiation may compriseother wavelengths of electromagnetic radiation. In some embodiments, thelight 720 comprises a substantially collimated beam of light to decreaseblurring at the edges of the supports 40 corresponding to the edges ofthe apertures of the mask. Alternatively or in combination, the beam oflight may comprise a low divergence beam, for example with a divergenceof no more than about 10 milliradians, to allow the beam of light to befocused substantially to a point on the male side of the contact lensmold or the female side of the contact lens, for example. While the maskis show proximate an external surface of the mold in FIG. 7B,alternatively the mask can be imaged onto the layer 720 by use of one ormore suitable lenses between the layer 720 and the mask.

FIG. 8 shows a method 800 for fabricating a contact lens. The processmay start at step 810 where support material is placed on a mold. Afterthe support material placed on the mold the process may continue to step820 where the support material is cured on the mold. In someembodiments, at step 830 electromechanical components are placed on thecured support material that forms the supports. At step 840 the mold isfilled with lens material. After filling the mold with lens material, atstep 850 the lens material is cured. In some embodiments, at step 860lens cured lens material is hydrated and the completed contact lens isremoved from the mold.

In more detail, at step 810 the support material is placed on a mold.The support material may be contact lens material, such as a low orzero-swell contact lens material. In some embodiments, the contact lensmaterial may have a swell of between 0% and 2%. The swell of a materialrefers to the change in volume of the material between a cured andnon-hydrated state and dehydrated state.

Placing or depositing support material on a mold may be accomplished inmany ways. For example, in some embodiments, a layer of contact lensmaterial may be spin deposited onto the contact lens mold in order tocover the mold, as discussed herein with respect to FIGS. 5C, 5D, 5E,and 7B.

In some embodiments, depositing support material on the mold may includedepositing discrete volumes of material on the mold. For example, asshown and described herein with respect to FIGS. 5A and 5B. The supportsmaterial may be deposited on the surface of the mold while leaving thecentral optical zone clear of support material. In some embodiments, thesupports are individually deposited, one at a time, in an automatedprocess. In some embodiments, a computer numerical control machine (CNC)may be programmed to move to the desired locations and dispense a volumeof contact lens material onto the mold in order to form the support. Insome embodiments, the contact lens material may be deposited via apipette or other volumetric metering device. In some embodiments, anarray of dispensers arranged according to the desired locations of thesupports may simultaneously dispense a plurality of supports on theconcave mold. In some embodiments, a direct fabrication machine, such asa 3D printer, may deposit the contact lens material at the desiredlocations of the concave mold. In some embodiments, the depositedcontact lens material may be an uncured monomer. In some embodiments, inorder to facilitate deposition of the deposited contact lens material inthe desired locations, the contact lens material may be partially curedbefore it is deposited on the mold.

In some embodiments, prior to depositing the contact lens supportmaterial on the mold, a mask is placed on or in the mold. The mask mayhave wells, such as shown and described with respect to the maskdepicted in FIGS. 6A and 6B. Depositing the contact lens supportmaterial on the mold may include filling the wells of a mask with thecontact lens material, as described herein.

In some embodiments, depositing the support material on the mold mayinclude first depositing a thin layer of contact lens material on themold and then spin forming the thin layer contact lens material whichmay then be at least partially cured, as described herein, for examplewith respect to FIGS. 5C and 5D. After curing the thin layer, supportsmay be deposited onto the thin layer of contact lens material. Thesupports may be depo sited on the thin layer by any means. For example,in some embodiments, the supports are individually deposited, one at atime, in an automated process. In some embodiments, a computer numericalcontrol machine (CNC) may be programmed to move to the desired locationsand dispense a volume of contact lens material onto the thin layer inorder to form the support. In some embodiments, the contact lensmaterial may be deposited via a pipette for other volumetric meteringdevice. In some embodiments, an array of dispensers arranged accordingto the desired locations of the supports may simultaneously dispense aplurality of supports on the thin layer.

In some embodiments, a direct fabrication machine, such as a 3D printer,may deposit the contact lens material at the desired locations of thethin layer. In some embodiments, the contact lens material may be anuncured monomer. In some embodiments, in order to facilitate depositionof the contact lens material in the desired locations, the contact lensmaterial may be partially cured.

At step 820 the support material may be cured on the mold. In someembodiments, support material that has been deposited on the mold may beat least partially cured. The curing process may include exposing thesupport material to light such as UV radiation, heat, a combination ofheating and light such as UV radiation, or other curing process. In someembodiments, a UV light source projects UV light onto the supportmaterial to cure the supports. In some embodiments, the supports may bepartially cured such that the supports remain in place while uncuredsupport material is rinsed or washed off of the mold. In someembodiments, the supports may be at least partially cured that theuncured support material is not rinsed or washed off of the mold.

In some embodiments, prior to exposing the support material to UVradiation, a mask is placed between the UV light source and the supportmaterial in order to selectively cure the supports, as described herein.In some embodiments, for example those with a mask that includes wells,after curing the support material, the mask is removed from the moldwhile the cured contact lens material remains attached to the mold.

At step 830 electromechanical components are placed on the supports. Insome embodiments, the electromechanical components are assembledtogether and then deposited onto the supports. In some embodiments,prior to placing the electromechanical components onto the supports, theelectromechanical components may be pre-formed into a desired shape. Forexample, the electromechanical contact lens components may be pre-formedinto a curved shape that matches the curve shape of the contact lens.Pre-forming the electromechanical components may include placing theelectromechanical contact lens components between two curved jigs whichpress the contact lens components into a curved shape. In someembodiments, the electromechanical contact lens components are subjectedto heating, for example at 100° for one hour, while placed between thetwo curved jigs in order to set the curved shape in the contact lenscomponents.

In some embodiments, a pick and place machine may be used to place thecontact lens components onto the supports. In some embodiments, a CNCmachine may be used to place the contact lens components onto thesupports. In some embodiments, the contact lens components may bemanually placed onto the supports.

At step 840 the mold is filled with lens material. The mold may befilled with additional contact lens material. The contact lens materialmay be the same material used for the supports. In some embodiments, apipette for other volumetric metering device dispenses a preselectedamount of contact lens material into the mold. In some embodiments,filling the mold with contact lens material, the contact lens materialand mold may be subject to vibration in order to reduce or removepotential air pockets within the contact lens material. In someembodiments, the mold is a first mold and defines a first exteriorsurface of the contact lens. In some embodiments, a second mold isplaced over the contact lens material on or within the first mold inorder to define a second exterior surface of the contact lens. In someembodiments, the first mold defines a concave surface of the contactlens and the second mold defines a convex surface of the contact lens.In some embodiments, the first mold defines a convex surface of thecontact lens and the second mold defines a concave surface of thecontact lens.

At step 850 the lens material is cured. The curing process may includeexposure to light such as UV radiation, heat, a combination of heatingand light such as UV radiation, or other curing process. In someembodiments, a UV light source projects UV light onto the supportmaterial to cure the contact lens material. In some embodiments, thecontact lens material may be exposed to UV radiation for about 15seconds, about 30 seconds, about 45 seconds, about 60 seconds, or about75 seconds. In some embodiments, the lens material may be exposed to UVradiation for between 30 seconds and 90 seconds. In some embodiments,the contact lens material may be exposed to UV radiation for between 45seconds and 75 seconds.

At step 860 lens material is hydrated. In some embodiments, the curedcontact lens may be hydrated. In some embodiments, the cured contactlens is hydrated before it is removed from the mold. Hydrating thecontact lens within the mold may aid in removing the advocated contactlens from the mold. In some embodiments, the cured contact lens isremoved from the mold and then hydrated.

Although FIG. 8 shows a method 800 for fabricating a contact lens, inaccordance with some embodiments, one of ordinary skill in the art willrecognize many variations and adaptations. For example, the steps can beperformed in any order, some of the steps omitted, and some of the stepsrepeated. Also, some of the steps may comprise sub-steps of other steps.

FIGS. 9A and 9B depict an apparatus 900 for depositing pillars on acontact lens mold. In some embodiments, the location of depositionremains substantially fixed, and the contact lens mold is one or more ofrotated or translated to deposit pillars at a plurality of differentlocations on the contact lens mold. The apparatus 900 may include a baseportion 902 that is coupled to a dispensing portion 904 via an arm 906.The base portion 902 is configured to hold and position a contact lensmold 400. The base portion provides at least two rotational degrees offreedom to allow the contact lens mold 400 to be positionedappropriately beneath the dispenser portion 904 for the deposition ofmaterial on the contact lens mold 400.

A first rotational degree of freedom of the base portion may be providedby a swiveling or pivoting platform 912. The platform 912 may berotationally coupled to the base portion 902 along an axis of rotation914. The axis of rotation 914 provides the first rotational degree offreedom. The axis of rotation 914 may be perpendicular to an axis ofdeposition, such as the axis along which the dispensing portion 904 maytranslate or z-axis along which the dispensing conduit 940 extends. Insome embodiments, a distance between the axis of rotation 914 and thesurface of the mold 400 may be the same as the radius of curvature of asurface of the mold 400, such as the inner surface of the mold 400. Inthis way, a distance between the surface of the mold and the dispensingconduit 940 may be maintained when the platform 912 is rotated about theaxis of rotation 914. In some embodiments, the distance between thesurface of the mold 400 and the surface of the mold 400 may be greaterthan the radius of curvature of the contact lens.

A second rotational degree of freedom of the base portion may beprovided by a contact lens holder 916. The contact lens mold holder 916may be rotationally coupled to the pivoting platform 912 to allow thecontact lens mold holder 916 to rotate about an axis that isperpendicular to the rotational axis 914 of the pivoting platform 912.The second rotational degree of freedom allows the contact lens mold 400to be rotated beneath the dispensing conduit 940. In some embodiments,during use the contact lens mold 400 is positioned with respect to thedispensing conduit such that the dispensing conduit is located at aradial distance from the center of the contact lens mold 400. Then, insome embodiments, the contact lens mold may be rotated about the secondrotational axis in order to position the dispensing conduit 940 atconcentric locations on the contact lens mold about the center of thecontact lens mold without further movement of the base portion 912 aboutthe first rotational axis 914.

In some embodiments, the contact lens 916 may include markings orindications 918. The markings 918 may indicate a location for dispensingor applying the contact lens material onto the contact lens mold forforming a pillar. For example, the apparatus 900 includes six markings918 that mark the rotational locations for depositing the pillars on themold 400. In some embodiments, the markings 918 may be physical detentsor other mechanical indexing structures that releasably hold the at theindicated rotational locations.

The dispensing portion 904 may include a movable head portion 934. Thehead portion 934 may be configured to translate along an axisperpendicular to the rotational axis 914. A rack and pinion system 932connected to a shaft may facilitate the translation of the dispensingportion 914 and the movable head portion 934. The translation axis maybe parallel to or coincide with the length of the shaft of the rack andpinion system 932. Translation of the movable head portion 934 allowsthe end of the dispensing conduit 940 to be positioned on or near thesurface of the contact lens mold 400. In some embodiments, the end ofthe dispensing conduit 940 may be positioned a distance from the contactlens mold that is less than or equal to the height of a pillar. In someembodiments the end of the dispensing conduit 940 may be positioned adistance of less than half the height of a pillar.

In some embodiments, a handle 930 may the coupled to the pinion of therack and pinion system. Movement or rotation of the handle may causerotation of the pinion and translation of the rack which may result intranslation of the movable head portion 934.

In some embodiments the dispensing conduit 940 may be a needle, a hollowtube, or other elongated hollow structure. In some embodiments, aninternal diameter of the dispensing conduit 940 may be less than orequal to the diameter of a pillar. In some embodiments, the internaldiameter of the dispensing conduit 940 may be less than half thediameter of a pillar. In some embodiments, the internal diameter of theconduit may be between about 0.01 mm and about 0.5 mm.

The head portion 934 may include a fluid intake port 932 verticallycoupled to a dispensing conduit 940. The fluid intake port 932 may be areservoir that feeds the dispensing conduit 940 through gravity orcapillary action. In some embodiments, the fluid intake port 932 mayinclude or otherwise the be fluidically coupled to a pressurized fluidreservoir for holding and dispensing contact lens material forfabricating pillars.

Although reference is made to apparatus 900 comprising a handle, thisapparatus may comprise an at least partially automated robotic apparatusconfigured with one or more robotic components, such as linkages andmotors to move the components, and these movable components can becontrolled with a processor configured with instructions to depositpillars as described herein.

FIG. 10 shows an image of in experimental support 40 formed according tothe systems and methods discussed herein. The support 40 is shown on amold 400 after removal of uncured support material.

FIG. 11 shows an image of an experimental contact lens 10 with supportsformed according to the systems and methods discussed herein. Thecontact lens 10 is shown before removal from the mold. The contact lens10 is encapsulated between a convex mold 400 a and a concave mold 400.No electromechanical components are encapsulated within the experimentalcontact lens 10. The support is shown extending from the concave surfaceof the contact lens with a height of about one half the thickness of thecontact lens.

FIGS. 12 and 13 show an experimental contact lens 10 formed withelectromechanical components encapsulated within the contact lens 10 andsupported by a plurality of supports. The supports 40 are shownsupporting various portions of the electromechanical components. Forexample, the contact lens 10 includes supports that support the antenna41, the sensors 22, the PCB 24, and the light sources 12. The contactlens 10 includes no supports within the clear central portion 14 of thecontact lens. The experimental contact lens 10 also includes supportssupport multiple components in some supports placed in locations withoutany components.

As described herein, the computing devices and systems described and/orillustrated herein broadly represent any type or form of computingdevice or system capable of executing computer-readable instructions,such as those contained within the modules described herein. In theirmost basic configuration, these computing device(s) may each comprise atleast one memory device and at least one physical processor.

The term “memory” or “memory device,” as used herein, generallyrepresents any type or form of volatile or non-volatile storage deviceor medium capable of storing data and/or computer-readable instructions.In one example, a memory device may store, load, and/or maintain one ormore of the modules described herein. Examples of memory devicescomprise, without limitation, Random Access Memory (RAM), Read OnlyMemory (ROM), flash memory, Hard Disk Drives (HDDs), Solid-State Drives(SSDs), optical disk drives, caches, variations or combinations of oneor more of the same, or any other suitable storage memory.

In addition, the term “processor” or “physical processor,” as usedherein, generally refers to any type or form of hardware-implementedprocessing unit capable of interpreting and/or executingcomputer-readable instructions. In one example, a physical processor mayaccess and/or modify one or more modules stored in the above-describedmemory device. Examples of physical processors comprise, withoutlimitation, microprocessors, microcontrollers, Central Processing Units(CPUs), Field-Programmable Gate Arrays (FPGAs) that implement softcoreprocessors, Application-Specific Integrated Circuits (ASICs), portionsof one or more of the same, variations or combinations of one or more ofthe same, or any other suitable physical processor. The processor maycomprise a distributed processor system, e.g. running parallelprocessors, or a remote processor such as a server, and combinationsthereof.

Although illustrated as separate elements, the method steps describedand/or illustrated herein may represent portions of a singleapplication. In addition, in some embodiments, one or more of thesesteps may represent or correspond to one or more software applicationsor programs that, when executed by a computing device, may cause thecomputing device to perform one or more tasks, such as the method step.

In addition, one or more of the devices described herein may transformdata, physical devices, and/or representations of physical devices fromone form to another. Additionally or alternatively, one or more of themodules recited herein may transform a processor, volatile memory,non-volatile memory, and/or any other portion of a physical computingdevice from one form of computing device to another form of computingdevice by executing on the computing device, storing data on thecomputing device, and/or otherwise interacting with the computingdevice.

The term “computer-readable medium,” as used herein, generally refers toany form of device, carrier, or medium capable of storing or carryingcomputer-readable instructions. Examples of computer-readable mediacomprise, without limitation, transmission-type media, such as carrierwaves, and non-transitory-type media, such as magnetic-storage media(e.g., hard disk drives, tape drives, and floppy disks), optical-storagemedia (e.g., Compact Disks (CDs), Digital Video Disks (DVDs), andBLU-RAY disks), electronic-storage media (e.g., solid-state drives andflash media), and other distribution systems.

A person of ordinary skill in the art will recognize that any process ormethod disclosed herein can be modified in many ways. The processparameters and sequence of the steps described and/or illustrated hereinare given by way of example only and can be varied as desired. Forexample, while the steps illustrated and/or described herein may beshown or discussed in a particular order, these steps do not necessarilyneed to be performed in the order illustrated or discussed.

The various exemplary methods described and/or illustrated herein mayalso omit one or more of the steps described or illustrated herein orcomprise additional steps in addition to those disclosed. Further, astep of any method as disclosed herein can be combined with any one ormore steps of any other method as disclosed herein.

The processor as described herein can be configured to perform one ormore steps of any method disclosed herein. Alternatively or incombination, the processor can be configured to combine one or moresteps of one or more methods as disclosed herein.

Unless otherwise noted, the terms “connected to” and “coupled to” (andtheir derivatives), as used in the specification and claims, are to beconstrued as permitting both direct and indirect (i.e., via otherelements or components) connection. In addition, the terms “a” or “an,”as used in the specification and claims, are to be construed as meaning“at least one of” Finally, for ease of use, the terms “including” and“having” (and their derivatives), as used in the specification andclaims, are interchangeable with and shall have the same meaning as theword “comprising.

The processor as disclosed herein can be configured with instructions toperform any one or more steps of any method as disclosed herein.

It will be understood that although the terms “first,” “second,”“third”, etc. may be used herein to describe various layers, elements,components, regions or sections without referring to any particularorder or sequence of events. These terms are merely used to distinguishone layer, element, component, region or section from another layer,element, component, region or section. A first layer, element,component, region or section as described herein could be referred to asa second layer, element, component, region or section without departingfrom the teachings of the present disclosure.

As used herein, the term “or” is used inclusively to refer items in thealternative and in combination.

As used herein, characters such as numerals refer to like elements.

The present disclosure includes the following numbered clauses.

Clause 1. A contact lens comprising: a body of contact lens materialextending between a first surface and a second surface; anelectromechanical component supported in the contact lens materialbetween the first surface and the second surface; and a support formedof the contact lens material extending from at least one of the firstsurface or the second surface to the electromechanical component.

Clause 2. The contact lens of clause 1, wherein the support comprises aplurality of supports each extending from one of the first surface andthe second surface to the electromechanical component.

Clause 3. The contact lens of clause 1, wherein the electromechanicalcomponent has a first shape and wherein the support is formed with asecond shape that corresponds to the first shape.

Clause 4. The contact lens of clause 3, wherein the second shape is thesame as the first shape.

Clause 5. The contact lens of clause 1, wherein the support extends fromat least one of the first surface and the second surface with a heightof at least 0.020 mm.

Clause 6. The contact lens of clause 1, wherein the support extends fromat least one of the first surface and the second surface with a heightof between 0.020 mm and 0.3 mm.

Clause 7. The contact lens of clause 2, wherein the supports have awidth or diameter of at least 0.020 mm.

Clause 8. The contact lens of clause 2, wherein the supports have awidth of diameter of between 0.020 mm and 2 mm.

Clause 9. The contact lens of clause 1, wherein a first distance extendsbetween the first surface and the second surface and wherein the supportextends from at least of the first surface and the second surface with aheight of between 30% and 70% of the first distance.

Clause 10. The contact lens of clause 1, wherein a first distanceextends between the first surface and the second surface and wherein thesupport extends from at least of the first surface and the secondsurface with a height of less than 50% of the first distance.

Clause 11. The contact lens of clause 1, wherein the support has avolume of between 0.005 uL and 0.5 uL.

Clause 12. The contact lens of clause 1, wherein the support has avolume of between 0.01 uL and 0.1 uL.

Clause 13. The contact lens of clause 1, wherein the electromechanicalcomponent includes one or more of a flexible PCB, a power source, aprocessor, and a light source.

Clause 14. The contact lens of clause 1, wherein the electromechanicalcomponent includes a pre-formed flexible PCB having a hemisphericalshape.

Clause 15. The contact lens of clause 2, wherein the plurality ofsupports is arranged in two concentric rings about a clear central zone.

Clause 16. The contact lens of clause 2, wherein the plurality ofsupports is arranged in a first density to support of first portion ofthe electromechanical components and in a second density to support asecond portion of the electromechanical components.

Clause 17. The contact lens of clause 2, wherein the plurality ofsupports is arranged with a distance of between 0.10 mm and 1.0 mm fromeach other.

Clause 18. The contact lens of clause 2, wherein the plurality ofsupports has a width and are arranged with a distance of between 0.2widths and 5 widths from each other.

Clause 19. The contact lens of clause 1, wherein the contact lensmaterial comprises a material with a swell of 0% to 2%.

Clause 20. A method of fabricating a contact lens, the methodcomprising: forming a support of contact lens material on a firstcontact lens mold; partially curing the support; placingelectromechanical components on the support; filling the mold withcontact lens material; and curing the contact lens material.

Clause 21. The method of clause 20, wherein forming the support ofcontact lens material on the first contact lens mold comprises: placinga mask having wells over the first mold; and filling the mask wells withcontact lens material.

Clause 22. The method of clause 20, wherein forming the support ofcontact lens material on the first contact lens mold comprises: coatingthe first mold with contact lens material, and placing a mask havingapertures over the mold; and wherein partially curing the supportcomprises exposing the contact lens material to curing radiation throughthe apertures in the mask.

Clause 23. The method of clause 22, wherein forming the support ofcontact lens material on the first contact lens mold comprises: spinforming the coating on the mold.

Clause 24. The method of clause 20, wherein forming the support ofcontact lens material on the first contact lens mold comprises: spinforming a coating with a thickness of between 0.001 mm and 0.05 mm onthe first mold with contact lens material, and at least partially curingthe coating; and forming the support on the at least partially curedcoating.

Clause 25. The method of clause 20, further comprising hydrating thecured contact lens material.

Clause 26. The method of clause 20, wherein the support comprises aplurality of supports.

Clause 27. The method of clause 20, wherein the electromechanicalcomponent has a first shape and wherein the support is formed with asecond shape the corresponds to the first shape.

Clause 28. The method of clause 27, wherein the second shape is the sameas the first shape.

Clause 29. The method of any one of clauses 20-24, wherein the supporthas height of at least 0.020 mm.

Clause 30. The method of any one of clauses 20-24, wherein the supporthas a height of between 0.020 mm and 0.3 mm.

Clause 31. The method of any one of clauses 20-24, wherein the supportshave a width or diameter of at least 0.020 mm.

Clause 32. The method of any one of clauses 20-24, wherein the supportshave a width of diameter of between 0.020 mm and 2 mm.

Clause 33. The method of any one of clauses 20-24, wherein the supportshave a height of between 30% and 70% of a final thickness of the contactlens.

Clause 34. The method of any one of clauses 20-24, wherein the supportshave a height of less than 50% of a final thickness of the contact lens.

Clause 35. The method of any one of clauses 20-24, wherein the supporthas a volume of between 0.005 uL and 0.5 uL.

Clause 36. The method of any one of clauses 20-24, wherein the supporthas a volume of between 0.01 uL and 0.1 uL.

Clause 37. The method of any one of clauses 20-24, wherein theelectromechanical component includes one or more of a flexible PCB, apower source, a processor, and a light source.

Clause 38. The method of any one of clauses 20-24, wherein theelectromechanical component includes a pre-formed flexible PCB having ahemispherical shape.

Clause 39. The method of any one of clauses 20-24, further comprising:pre-forming a flexible PCB into a hemispherical shape.

Clause 40. The method of any one of clauses 20-24, wherein the pluralityof supports is arranged in two concentric rings about a clear centralzone.

Clause 41. The method of any one of clauses 20-24, wherein the pluralityof supports is arranged in a first density to support of first portionof the electromechanical components and in a second density to support asecond portion of the electromechanical components.

Clause 42. The method of any one of clauses 20-24, wherein the pluralityof supports is arranged with a distance of between 0.10 mm and 1.0 mmfrom each other.

Clause 43. The method of any one of clauses 20-24, wherein the pluralityof supports has a width and are arranged with a distance of between 0.2widths and 5 widths from each other.

Clause 44. The method of any one of clauses 20-24, wherein the contactlens material comprises a material with 0% to 2% swell.

Clause 45. The method of any one of clauses 20-24, wherein partiallycuring the support comprises UV curing, heat curing, or both UV and heatcuring.

Clause 46. The method of any one of clauses 20-24, wherein partiallycuring the contact lens comprises UV curing, heat curing, or both UV andheat curing.

Clause 47. An apparatus for fabricating pillars, the apparatuscomprising: a moveable head portion comprising a dispenser and beingmoveable along a first translational axis; a base comprising a contactlens mold holder and configured to move the contact lens mold about afirst and a second axis of rotation; and an arm that couples the headportion to the base.

Clause 48. The apparatus of clause 47, wherein the moveable head portionand the dispense translate along the first translational axis.

Clause 49. The apparatus of clause 47, wherein the first axis ofrotation and the second axis of rotation are perpendicular to eachother.

Clause 50. The apparatus of clause 47, wherein the first axis ofrotation is configured to position the contact lens mold beneath adispensing conduit of the moveable head portion with a dispensing end ofthe dispensing conduit offset from a center of the contact lens mold.

Clause 51. The apparatus of clause 50, wherein the second axis ofrotation is configured to rotate the contact lens mold while maintainingthe offset of the conduit from the center of the contact lens mold.

Clause 52. The apparatus of clause 49, wherein the first axis ofrotation is perpendicular to the first translational axis.

Clause 53. The apparatus of clause 47, wherein the contact lens moldholder is rotationally coupled to the base and configured to rotateabout the second axis of rotation.

Clause 54. The apparatus of clause 53, wherein the contact lens holdholder includes a plurality of indexes.

Clause 55. The apparatus of clause 54, wherein the indexes are detents.

Clause 56. The apparatus of clause 47, wherein the moveable head portionfurther comprises a rack and pinion for translating the moveable headportion along the first translation axis.

Clause 57. The contact lens, method or apparatus of any one of thepreceding clauses, wherein one or more supports is dimensioned toposition a flexible printed circuit board (PCB) with a gap between theflex PCB and a contact lens mold from which the one or more supportsextends.

Clause 58. The contact lens, method or apparatus of clause 57, whereinthe one or more supports comprises a plurality of supports and whereinthe gap between the flex PCB and the contact lens mold extends aroundeach of the plurality of supports.

Clause 59. The contact lens, method or apparatus of clause 57, whereinthe gap is dimensioned to receive flowable material for curing to formthe contact lens body.

Clause 60. The contact lens, method or apparatus of clause 59, whereinthe gap comprises distance extending from flex PCB toward the contactlens mold and is within a range from 0.010 mm to 0.3 mm and optionallywithin a range from 0.040 mm to 0.2 mm.

Embodiments of the present disclosure have been shown and described asset forth herein and are provided by way of example only. One ofordinary skill in the art will recognize numerous adaptations, changes,variations and substitutions without departing from the scope of thepresent disclosure. Several alternatives and combinations of theembodiments disclosed herein may be utilized without departing from thescope of the present disclosure and the inventions disclosed herein.Therefore, the scope of the presently disclosed inventions shall bedefined solely by the scope of the appended claims and the equivalentsthereof.

What is claimed is:
 1. A method of fabricating a contact lens, themethod comprising: forming a support of a contact lens material on afirst contact lens mold; partially curing the support; placingelectromechanical components on the support; filling a mold with thecontact lens material, the mold comprising the first contact lens moldand a second contact lens mold with the electromechanical componentstherebetween; and curing the contact lens material.
 2. The method ofclaim 1, wherein forming the support of contact lens material on thefirst contact lens mold comprises: placing a mask having wells over thefirst mold; and filling the mask wells with contact lens material. 3.The method of claim 1, wherein forming the support of contact lensmaterial on the first contact lens mold comprises: coating the firstmold with contact lens material, and placing a mask having aperturesover the mold; and wherein partially curing the support comprisesexposing the contact lens material to curing radiation through theapertures in the mask.
 4. The method of claim 3, wherein forming thesupport of contact lens material on the first contact lens moldcomprises: spin forming the coating on the first contact lens mold. 5.The method of claim 1, wherein forming the support of contact lensmaterial on the first contact lens mold comprises: spin forming acoating with a thickness of between 0.001 mm and 0.05 mm on the firstcontact lens mold with contact lens material, and at least partiallycuring the coating; and forming the support on the at least partiallycured coating.
 6. The method of claim 1, further comprising hydratingthe cured contact lens material.
 7. The method of claim 1, wherein thesupport comprises a plurality of supports extending between the firstcontact lens mold and the electromechanical components.
 8. The method ofclaim 1, wherein the electromechanical component has a first shape andwherein the support is formed with a second shape the corresponds to thefirst shape.
 9. The method of claim 8, wherein the second shape is thesame as the first shape.
 10. The method of claim 1, wherein the supporthas a height of between 0.020 mm and 0.3 mm, a width of between 0.020 mmand 2 mm, and a height of between 30% and 70% of a final thickness ofthe contact lens.
 11. The method of claim 1, wherein the support has avolume of between 0.005 uL and 0.5 uL.
 12. The method of claim 1,wherein the electromechanical component includes one or more of aflexible PCB, a power source, a processor, and a light source.
 13. Themethod of claim 1, wherein the electromechanical component comprises apre-formed flexible PCB having a hemispherical shape.
 14. The method ofclaim 1, wherein the support comprises a plurality of supports arrangedin two concentric rings about a clear central zone.
 15. The method ofclaim 1, wherein the support comprises a plurality of supports arrangedin a first density to support of first portion of the electromechanicalcomponents and in a second density to support a second portion of theelectromechanical components.
 16. The method of claim 1, wherein thesupport comprises a plurality of supports each having a width andarranged with a distance of between 0.2 widths and 5 widths from eachother and optionally wherein the distance is between 0.10 mm and 1.0 mm.17. The method of claim 1, wherein the contact lens material comprises amaterial with 0% to 2% swell.
 18. The method of claim 1, whereinpartially curing the support comprises one or more of UV curing or heatcuring.
 19. The method of claim 1, wherein the support is formed with afirst contact lens material prior to filling the mold and wherein themold is filled with a second contact lens material, the first contactlens material substantially the same as the second contact lensmaterial.
 20. The method of claim 19, wherein the partially curedsupport formed of the first contact lens material and the second contactlens material filling the mold are fully cured together prior toremoving the contact lens from between the first mold and the secondmold.